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^1 




BUREAU OF MINES 
INFORMATION CIRCULAR/1988 



j>-i 




A Testbed for Autonomous Mining 
IVIachine Experiments 



By William H. Schiffbauer 



UNITED STATES DEPARTMENT OF THE INTERIOR 



Information Circular 9198 



A Testbed for Autonomous Mining 
IVIachine Experiments 



By William H. Schiffbauer 



UNITED STATES DEPARTMENT OF THE INTERIOR 
Donald Paul Model, Secretary 

BUREAU OF MINES 
T S Ary, Director 



Library of Congress Cataloging in Publication Data; 






Schiffbauer, William H. 

A testbed for autonomous mining machine experiments. 

(Bureau of Mines information circular; 9198) 

Includes bibliographical references. 

Supt. of Docs.: 128.27: 9198. 

1. Mining machinery-Computer simulation. I. Title. II. Series: Information 
circular (United States. Bureau of Mines); 9198. 

-TN295.U4 [TN345] 622 s [622'. 028] 88-600360 



CONTENTS 

Page 

Abs t ract 1 

Introduction 2 

Design objectives 3 

Operating system software description 3 

Programming language description 4 

Hardware description <> 4 

Application software 8 

Modes of operation 8 

System diagnostics mode 8 

System exerciser mode 8 

Closed loop mode 8 

Browser mode 9 

Scripting mode 9 

System Integrity software 9 

System confidence tests 9 

Monitor 9 

TAMME Initialization 9 

Watchdog timer 9 

Local user operation 10 

Summary -. 20 

ILLUSTRATIONS 

1. Joy 16 CM mining machine 2 

2. Operating system and hardware devices 3 

3. TAMME hardware 4 

4. Bubble memory cartridge 6 

5. Menu flowchart 11 

6. Closed loop test algorithm 14 

7. TAMME and bltbus network 20 

TABLES 

1. Sensor connections to TAMME 7 

2. Dlgltlal I-O channel assignments 8 





UNIT OF MEASURE 


ABBREVIATIONS 


USED 


IN 


THIS REPORT 


A 


ampere 




psl 




pound per square inch 


op 


degree Fahrenheit. 




psia 




pound per square inch, 
absolute 


ft 


foot 




s 




second 


gpm 


gallon per minute 




St 




short ton 


in 


inch 




V 




volt 


ym 


micrometer 




w 




watt 


Mb 


megabyte 










MHz 


megahertz 











A TESTBED FOR AUTONOMOUS MINING MACHINE EXPERIMENTS 

By William H. Schiffbauer^ 



ABSTRACT 

The Bureau of Mines is conducting research that is aimed at making the 
mining industry more efficient in terms of both productivity and the 
health and safety of the worker. As part of this research the Bureau of 
Mines has integrated a testbed composed of computer and related periph- 
eral hardware to form an intelligent base for performing autonomous min- 
ing machine experiments. Although this particular application was con- 
figured for use on a Joy 16 CM mining machine, its generic structure 
facilitates its attachment to a variety of mining machine types. The 
multitasking multiuser computer can be set up for other applications by 
changing a bubble memory cartridge. The Joy 16 CM implementation in- 
cludes 96 digital input-output (I-O) ports, 32 analog inputs, 8 analog 
outputs, 2 serial data channels, and 1 printer port. Operation of the 
machine can be performed either through a local terminal or remotely 
through a modem hookup. This report describes a testbed for autonomous 
mining machine experiments (TAMME) — its hardware, software, and complete 
system integration — so that it can be used as a foundation for other 
applications. 

^Electronics technician, Pittsburgh Research Center, Bureau of Mines, Pittsburgh, PA. 



INTRODUCTION 



Major problems threaten today's coal 
mining industry. Most of these problems 
can be traced to basic economics; i.e., 
providing a product that is both competi- 
tive and profitable. Through research, 
the Bureau of Mines is developing methods 
and devices that show promise in assist- 
ing private industry in making a competi- 
tive and profitable product, and also 
helping the workers to achieve these 
goals in a safe working environment. 

The TAMME system developed by the Bu- 
reau shows great promise toward making 
mining machinery more productive and safe 
for the workers by enhancing it with the 
latest computer technology. The TAMME is 
a collection of computer and peripheral 
devices, integrated into one chassis, and 
programmed to operate a Joy 16 CM mining 
machine (fig. 1). A modular I-O struc- 
ture permits attachment of TAMME to 
present and future monitoring or control 
devices. The hardware selected employs 
transformer and optical coupling, provid- 
ing extreme isolation from the noisy 
electrical environment presented by a 
mining machine. Additionally, a special 



power supply is used. The power supply, 
with transformer isolation and special 
circuit design, prevents any power fluc- 
tuations from entering the TAMME chassis. 
Throughout the hardware and software are 
a variety of diagnostic features that 
give the operator a status report of 
system health. Included in the design is 
a removable storage device called a 
bubble memory cartridge, that provides 
storage of operating system and applica- 
tion programs. The flexibility provided 
by TAMME allows it to be reconfigured for 
almost any monitoring and control 
application. 

The Bureau has created a tool that is 
useful for both research and production. 
It was constructed from a variety of off- 
the-shelf hardware and software so that 
its structure can be duplicated with a 
minimum of customization. Although this 
application of TAMME was specific to a 
Joy 16 CM mining machine, it can be 
easily applied to other mining machine 
types through modification of the 
software. 




FIGURE l.-Joy 16 CM mining machine. 



DESIGN OBJECTIVES 



The creation of TAMME was initiated to 
provide a base or testbed on a mining 
machine to allow Bureau researchers to 
experiment with making mining machinery 
autonomous, with the purpose of increas- 
ing production and making raining safer. 
The testbed was constructed with the 
latest technology and standardized inter- 
faces so that the product could evolve 
with the types of experiments being per- 
formed. The first step of the process 
was to establish control of the primary 
appendages of the machine without worry- 
ing about the actual position of the 
appendages. Then, with the help of the 
appropriate sensors, all of the append- 
ages and crucial systems on the machine 
were to be monitored, including the elec- 
trical and hyraulic systems. Next, 
closed loop control of the primary ap- 
pendages of the machine was to be estab- 
lished using the output of the sensors as 
a verification of position. The next 
objective was to produce a scripting mode 
of operation, to demonstrate a series of 
mining cycles completely controlled by 
the computer. This objective would be 
the starting point of the next phase of 
this ongoing research. 

Additionally, a major goal was to docu- 
ment TAMME so that industry personnel 
could duplicate and use it on their own 
machines for research or production. 

OPERATING SYSTEM SOFTWARE DESCRIPTION 

An Intel Corp. 2 iRMX86 operating system 
was used to form the software foundation 
for controlling the TAMME system. The 
iRMX86 was used because it is a real- 
time, multitasking, multiuser, custom- 
configurable operating system designed to 
support high-performance, time-critical 
applications. Because both iRMX86 and 
the host central processing unit (iSBC 
286/12) are provided and supported by the 
same manufacturer, their choice as a team 

^Reference to specific products does 
not imply endorsement by the Bureau of 
Mines. 



minimized the hardware-software failure 
bottleneck usually associated with system 
development. 

The customized iRMX86 operating system 
used on TAMME is activated on powerup. 
Once activated it creates a collection of 
simultaneously executing software appli- 
cations, called jobs, that provide soft- 
ware interfaces to the various pieces of 
the TAMME system. The jobs most visible 
to the system user are the human inter- 
face job and the extended I-O job. Other 
jobs are created but their purposes are 
beyond the scope of this paper. 

The human interface job gives the users 
and applications simple access to file 
and system management capabilities. 
Using support from other iRMX86 jobs, the 
human interface provides two simultaneous 
users for the TAMME system, a local user 
and a remote user. 

The extended 1-0 job is a group of 
software modules that provide users with 
system calls for direct management of 
hardware including the bubble memory, 
random access memory (RAM), interrupts, 
and 1-0 devices. 

Figure 2 shows the operating system 
environment and the hardware peripheral 
devices. 



Bubble 
memory 



Serial 
port 



Terminal 




Serial 
port 



Modem 




Parallel 
port 



Printer 



Analog 1-0 Digital 1-0 



FIGURE 2.-0peratmg system and hardware devices. 



PROGRAMMING LANQUAGE DESCRIPTION 

All of the application programs created 
for TAMME were done in the PLM 86 
programming language. PLM 86 is an Intel 
microcomputer-specific, block-structured, 
high-level language, that provides full 
access to the microcomputer architecture. 

Use of PLM 86 simplified the process of 
breaking up the software into individual 
modules dedicated to specific system 
tasks, which speeds up software produc- 
tion and minimizes bugs. 

HARDWARE DESCRIPTION 

A large collection of hardware formed 
the TAMME system. Hardware selection was 



carefully done to provide a base that was 
modular and standardized so that it could 
be reconfigured to an evolving series of 
experiments with a minimum of complica- 
tions. A portion of the TAMME system was 
designed using a previous Bureau develop- 
ment as a guide. -^ The present package of 
hardware is shown in figure 3. A de- 
scription of each of the components used 
to construct TAMME follows. 

■^Schif fbauer, W. H. An Intelligent 
Remotely Operated Controller for Mining 
Machines. Paper in Proceedings of the 
Third Conference on the Use of Computers 
in the Coal Industry, ed. by Y. J. Wang, 
R. L. Grayson, and R. L. Sanford. A. A. 
Balkema, 1986, pp. 223-233. 




FIGURE 3.-TAMME hardware. 



Multibus I Backplane, Electronic 
Solutions, Nine-Slot Chassis 

Multibus I is an industry standard'^ 
microcomputer bus structure, that sup- 
ports distributed processing configura- 
tions using multiple processors, I-O 
boards, and peripheral boards. 

Multibus I was selected because of its 
extreme adaptability, and the large num- 
ber of commercially available devices 
that conform to this standard. 

Central Processing Unit (CPU) board , 
Intel iSBC 286/12 

The iSBC 286/12 single-board computer 
is a high-performance 16-bit microcom- 
puter. It includes an 8-MHz 80286 micro- 
processor, together with a high-perfor- 
mance 80287 numeric data coprocessor and 
1 Mb of zero-wait state memory. Addi- 
tionally, it has multiple serial and 
parallel expansion ports, and other 
expansion capabilities through two multi- 
module bus connections and the multibus 
card edge interface. 

The iSBC 286/12 card was the choice for 
TAMME system because at the time of 
selection, it was the newest state- 
of-the-art microcomputer board that could 
provide a real-time control system. 

Bubble Memory, TARGA Electronics, 
Solidrive 

The Solidrive consists of a removable 
0.5 Mb bubble cartridge and a drive chas- 
sis. The drive chassis is mechanically 
and electrically configured to replace a 
standard 5-1/4-in half-height floppy disk 
drive. The bubble cartridge is used just 
as a floppy disk is used. 

The data stored in the bubble cartridge 
are permanently retained in the nonvola- 
tile, solid-state, magnetic bubble mem- 
ory. Once stored, data will be retained 
indefinitely without external power until 

^Institute of Electrical and Electronic 
Engineer, IEEE Standard 796, System Back- 
plane Bus. 



they are intentionally overwritten or 
erased. The contents of the bubble car- 
tridge may be altered as often as is 
required since bubble memory is not sub- 
ject to read-write-erase wear out. 

The bubble memory cartridge was chosen 
over a floppy disk or Winchester disk, 
because bubble memory is immune to the 
effects of mechanical vibration because 
it has no moving parts. Figure 4 shows 
the Solidrive and the bubble memory 
cartridge. 

Sensor Conditioning Modules, Analog 
Devices, 3B series 

Each of the sensors attached to the 
mining machine are connected to TAMME 
through a conditioning module (see table 
1). The 3B series of conditioning 
modules were chosen because they use 
transformer coupling, which provides max- 
imum mining machine electrical system 
isolation, and also because there are 
modules available for a large variety of 
sensor types. 

Analog-to-Digital Converter Card, Analog 
Devices, RTI 711 

The RTI 711 is a complete single-board 
analog input card that interfaces with 
multibus-compatible computer hardware. 
It provides 32 channels of 12-bit resolu- 
tion, single-ended inputs, and has high 
common mode noise rejection. 

The RTI 711 was selected because it was 
compatible with the remainder of the 
system, required only a single supply 
voltage, and its power consumption was 
quite low. 

Digital-to-Analog Converter Card, Intel 
iSBX328 

The iSBX 328 is a 16-channel 12-bit 
resolution device. 

This digital-to-analog converter was 
selected over other devices because of 
the number of channels provided in a com- 
pact package. 




FIGURE 4.-Bubble memory cartridge. 



Digital Input-Output, Opto 22 

Opto 22 devices are a series of remov- 
able input or output modules that are 
optically isolated and can be used for 
both ac and dc signals with resistive 
and inductive loads. They provide com- 
plete electrical isolation between the 
computer to the control system, a main 
reason for their choice for the TAMME 
system. 

The TAMME system is presently config- 
ured to provide up to 96 inputs-outputs. 
The assignment of channels for the Joy 16 
CM machine is shown in table 2, 

Uninterruptible Power Supply (UPS), Til 
Electronics 

The 170-W UPS provides transformer 
isolation from the mine power system. It 



eliminates virtually all transients and 
power fluctuations through its unique 
circuit design. Additionally, this UPS 
generates multiple dc voltages to TAMME 
instead of supplying ac voltages as would 
other power supplies. This feature 
eliminates an extra step in the power 
conversion process, makes the UPS more 
efficient, and consumes less power, 
thereby generating less heat in the com- 
puter housing. 

Chassis Mounting Considerations 

The Joy 16 CM mining machine is not 
a very good base for mounting delicate 
computer hardware. The extreme vibra- 
tion provided by it would certainly 
destory an unprotected system. It has 



TABLE 1, - Sensor connections to TAMME 



Module 



Type 



Function 

Conveyor elevation 

Conveyor swing 

Left cutting motor current 

Right cutting motor current 

Gathering head elevation 

Hydraulic reservoir level , 

Hydraulic reservoir pressure ». 

Hydraulic solenoids current 

Input line voltage 

Main hydraulic return flow 

Left tram motor current 

Right tram motor current 

Gathering head conveyor motor current. 

Pump motor current 

Pilot filter pressure 

Main pump flow 

Pilot pump flow 

Pilot pump pressure 

Main pump pressure. 

Pilot pump temperature 

Main pump temperature 

Shear elevation 

Left tram distance 

Right tram distance 

Stabilizer elevation 

Stabilizer pressure 

not used. 



Units 



1.. 
2.. 
3.. 

4.. 
5., 
6., 
7.. 
8.. 
9.. 
10. 
11. 
12. 
13. 
14. 
15. 
16. 
17. 
18. 
19. 
20. 
21. 
22. 
23. 
24. 
25. 
26, 



3B31-03 
3B31-00 
3B31-03 
3B31-03 
3B31-00 
3B32-01 
3B 16-01 
3B31-03 
3B32-02 
3B31-03 
3B31-03 
3B31-03 
3B31-03 
3B31-03 
3B 16-01 
3B31-01 
3B31-01 
3B31-01 
3B31-01 
3B31-01 
3B31-01 
3B31-00 
3B31-03 
3B31-03 
3B31-03 
3B31-03 



0°-20°. 
0°-95°. 
0-400 A. 
0-400 A. 
0°-25''. 
0-16 in. 
0-25 psia. 
0-5 A. 
0-750 V. 
0-85 gpm. 
0-100 A. 
0-100 A. 
0-100 A. 
0-200 A. 
0-50 psia. 
0-30 gpm. 
0-20 gpm. 
0-2,000 psi. 
0-4,000 psi. 
50°-250° F. 
50°-250° F. 
0°-50°. 
0°-220.5 ft. 
0°-220.5 ft. 
0°-40°. 
0-5,000 psi. 



Modules 27 through 32 are 



been determined,^ via underground field 
measurements, that military standard 
MIL-STD-810B for tracked vehicles best 
represents the vibration environment for 
electronic components mounted on under- 
ground coal mining equipment. With the 
vibration environment in mind, a computer 

^Bartholomae, R. C, B. S. Murray, and 
R. Madden. Vibration Qualification of 
Electronic Instrumentation for Under- 
ground Coal Mining Machinery. BuMines 
IC 8883, 1982, 10 pp. 



chassis was constructed and then 
tested on a shaker table. The results 
identified the vibrational frequencies of 
the chassis. Knowing the mining machine 
and the computer chassis vibrational 
characteristics, a special set of soft 
vibration mounts with mechanical stops 
for shock suppression (Stock Drive Pro- 
ducts, model 10z38-0507) were procured 
for mounting the computer chassis on the 
mining machine. Their use minimized the 
computer chassis vibration. 



TABLE 2. - Digital I-O channel assignments 



Module 

Input (0DC5Q) 
1.1 

1.2 

1.3 

1.4 

2.1 

2.2 

2.3 

2.4 

3.1 

3.2 

3.3 

3.4 

4.1 

4.2 

4.3 

4.4 

5.1 

5.2 

5.3 



Function 



Module 

Input (0DC5Q) — Con. 
5.4 , 

6.1 

6.2 , 

6.3 

6.4 , 

7.1 

7.2 , 

7.3 

7.4 

8.1 

8.2 

8.3 

8.4 

Output (IDC5Q): 
9.1 

9.2 

9.3..... 

9.4 



Function 



Conveyor elevation 

up. 
Conveyor elevation 

down. 
Conveyor swing 

right. 
Conveyor swing left. 
Control safety 

latch. 
Gathering head down. 
Gathering head up. 
Drum extension in. 
Right tram slow. 
Left tram slow. 
Right tram reverse. 
Left tram reverse. 
Right tram forward. 
Left tram forward. 
Tram fast. 
Drum extension out. 
Stabilizer jack up. 
Stabilizer jack 

down. 
Gathering head 

extension in. 



Gathering head 
extension out. 
Not used. 
Conveyor reverse. 
Shear up. 
Shear down. 
Cutting control. 
Pump run control. 
Power control relay. 
Conveyor forward. 
Not used. 

Do. 

Do. 

Do. 

Pressure switch 10- 

ym filter (16 psi). 
Pressure switch 3-ym 

filter (16 psi). 
Pressure switch 10- 

\im filter (35 psi). 
Pressure switch 3- 

ym filter (35 psi). 



NOTE. — The remainder of the 96 1-0 ports are presently unused. 

APPLICATION SOFTWARE 



MODES OF OPERATION 

The applications created for TAMME are 
identified as modes of operation includ- 
ing the system diagnostics mode, the sys- 
tem exerciser mode, closed loop test 
mode, the browser mode, and the scripting 
mode. 

Each of these modes of operation and 
associated piece of software permit the 
system operator to perform some series of 
tests or functions. A brief description 
for each of the modes of operation 
follows. 

System Diagnostics Mode 

This mode was used only in the develop- 
ment process and is no longer active in 
the system. It provided the initial 
checkout of hardware, and insured that 



all devices were connected properly. It 
was left in the system for future use. 

System Exerciser Mode 

Each of the functions on the Joy 16 CM 
machine normally controlled by the 
machine operator can be operated using 
this open loop mode of test. Each of 
the appendages can be turned on for 
a length of time as selected by the 
user. No position feedback on the con- 
trolled appendage it used. This mode was 
created to obtain appendage control 
characteristics. 

Closed Loop Mode 

Several of the Joy 16 CM machine ap- 
pendages have sensors to validate their 
position. Use of this mode lets the 



researcher operate the appendage under 
closed loop control. Characteristics 
such as overshoot due to gear backlash, 
hydraulic system response times, and 
other machine control variables can be 
analyzed using this mode of operation. 

Browser Mode 

Provides the operator with a quick look 
at the present analog voltage outputs of 
all of the sensors attached to the TAMME 
conditioning modules. Although mainly 
used for situation diagnostics, it can 
be used for more complex machine 
analysis. 

Scripting Mode 

An operator can use this software to 
create a complete mining cycle script by 
using a menu to select and then chain 
together several machine functions. Once 
a complete script is formed, it can be 
executed by entry of a single keystroke 
on the operator terminal. Each of the 
entries in the script will execute 
sequentially and will continue to the end 
unless terminated by, the user. 

SYSTEM INTEGRITY SOFTWARE 

System Confidence Tests 

The system confidence tests (SCT) soft- 
ware is resident in the firmware of the 
CPU board. The SCT is activated on 
powerup. It tests the CPU board, its 
memory, its interrupts, and most of the 
peripheral hardware. The results of the 
SCT are displayed on the local terminal. 
If no errors are detected, the operator 
continues with the normal powerup 
sequence. However, if errors are de- 
tected, the tests identify a possible 
fault and the computer executes the moni- 
tor program. 

Monitor 

The monitor is a primary software 
application, resident in the firmware of 
the CPU board. It contains a collection 



of simple programs that provide file 
loading and diagnostic capabilities^ 

TAMME Initialization 

Initialization begins with plugging a 
bubble memory cartridge, containing the 
applications and the operating system, 
into TAMME. A terminal set at 9600 baud 
must be attached to TAMME 's local user 
port. Power is applied first to the min- 
ing machine and then to the TAMME chas- 
sis. Shortly, thereafter, the diagnostic 
software SCT begins testing of the CPU 
and attached hardware. If all systems 
check okay, the operator can load the 
operating system by typing b. This 
action puts the system into the human 
interface level of the operating system 
(fig. 2). Selection of the applications 
software is made at the human interface 
level. The application software package 
created for the Joy 16 CM machine is 
called TAMME. Typing TAMME into the 
keyboard starts the application. The 
first part of TAMME creates a special 
software task called the watchdog timer, 
which is a software implemented safety 
device. Next, two user I-O jobs are 
created that provide menu-driven inter- 
faces to a local terminal user and a 
remote terminal user. The system is now 
ready to perform any of the experiments 
as selected from the menus. 

Watchdog Timer 

This software task exists within the 
software application called TAMME, which 
is stored in the bubble memory cartridge. 
It is activated with the TAMME task and 
runs simultaneously with it. Its algo- 
rithm provides a CPU activity signal to 
external hardware. As long as the watch- 
dog timer is executing, a particular bit 
on a digital output port is being tog- 
geled. If the CPU experiences some 
failure, the watchdog timer task will 
stop and its output signal quits toggl- 
ing. External hardware, attached to 
the watchdog timer port, expects to see 
a toggling signal. When the toggling 
quits, power to computer control 



10 



circuitry is removed, thereby disabling 
the Joy 16 CM mining machine. This 
application was primarily instituted as 



a safety device because of the potential 
danger that an out-of-control, 50-st min- 
ing machine presents. 



LOCAL USER OPERATION 



The local user is the primary operator 
of the system. All of its features are 
provided through a menu-driven interface. 
The operator simply selects a function, 
provides parameters, and initiates a 
process. This section is a descriptive 
tutorial on the capabilities of the TAMME 
system. The information is presented 
this way because its the best method to 
detail the individual processes. Figure 
5 is a menu flowchart detailing the menu 
operation. 

MENU 1 
***************************************** 

System Exerciser Mode 

1. system diagnostics 

2. system exerciser 

3. closed loop tests 

4. browser mode 

5. scripting mode 

6. exit 

enter (1-6) -> 

********* *********^* *************** ****** 

System Exerciser Mode 

The system exerciser permits the opera- 
tor to test all controllable appendages 
on the machine without involving the use 
of any feedback sensor or other position 
determining devices. The machine append- 
ages are called primitives and are 
grouped into the types of control they 
provide. They include the latching prim- 
itives and momentary primitives. The 
latching primitives are appendages on the 
machine that are designed to be turned on 
or off for the duration of some part of a 
mining cycle. The momentary primitives 
are appendages that are used in short 
spurts during mining cycles. Testing of 
a primitive is done by first selecting a 
primitive type, and then entering an 
execution parameter. The selected 
appendage will then move in respect to 
the execution parameter. 



When the operator selects the system 
exerciser mode of operation, menu 2 is 
displayed. Here, the type of primitive 
function is selected. 

MENU 2 
***************************************** 

System Exerciser 

1. latching primitives 

2. momentary primitives 

enter (1-2) -> 
***************************************** 

Latching Primitives 

The latching primitives are a group of 
four machine-controllable functions that 
are designed to be latched on or off for 
the duration of a mining cycle. 

The latching primitive menu (menu 3) 
comes up first with the present status 
and then with a selection of control. As 
the operator selects an item he or she is 
prompted with menu 4. Exiting menu 4 
causes the Joy 16 CM to perform the 
selected operation. 

MENU 3 
***************************************** 

Latching Primitives Present Status 

conveyor forward off 

pump run control off 

control power relay off 

cutting motor control off 

Latching Primitives Menu 

1. conveyor forward 

2. pump run control 

3. control power relay 

4. cutting motor control 

5. turn off all latching primitives 

6. exit 

enter (1-6) -> 
***************************************** 



11 



System exerciser — 



Closed loop mode — 



-Latching primitives 
-Momentary primitives 



-Control table- 



-Simulated machine table- 



-Hysteresis table- 



-Execution mode- 



-Target 

-Requested ramp rate 

-Maximum target 

-Control ramp rate 
-Lag time 

-Ex_out 
-Ex_in 
-Dep_out 
-Dep_in 

-Machine data-full speed 
-Machine data-requested ramp rate 
-Simulated machine-full speed 
-Simulated machine-requested ramp rate 



Browser mode- 



Scripting mode 1 -Read a script 

I 

[-Write a script 

I 

I -Act out a script 

FIGURE 5.— Menu flowchart. 



MENU 4 
***************************************** 

conveyor forward 

1 to turn on 

2 to turn off 

enter (1-2) -> 
***************************************** 

Momentary Primitives 

The system exerciser menu (menu 2), 
item 2, provides control of the momentary 
primitives on the Joy 16 CM machine. The 



momentary primitives are appendages or 
other control devices that are designed 
to work intermittently during a mining 
cycle. Menu 5 provides the complete 
selection of available primitives. As a 
primitive is selected, the operator is 
asked to enter the amount of time that 
the primitive is to be executed. Entries 
from 0.01 to 99.99 s are permitted. Upon 
successful execution of a momentary prim- 
itive, an okay message is shown. Any 
error messages shown will Indicate 
reasons for failures to complete a timed 
target value. 



12 



MENU 5 
***************************************************************************** 



Momentary Primitives Menu 

1-conveyor elevation up 
4-conveyor swing left 
7-gathering head up 
10-left tram slow 
13-right tram forward 
16-drum extension out 
19-gathering head ext in 
22-shear up 

24-tram lo speed forward 
27-tram hi speed reverse 
30-tram reverse turn rt 
33-pivot left 



2-conveyor elevation down 
5-control safety latch 
8-drum extension in 
11-right tram reverse 
14-left tram forward 
17-stab jack up 
20-gathering head ext out 
23-shear down 

25-tram high speed forward 
28-tram forward turn right 
31-tram reverse turn left 
34-return to main menu 



3-conveyor swing right 
6-gathering head down 
9-right tram slow 
12-left tram reverse 
15-fast tram 
18-stab jack down 
2 1-conveyor reverse 

26-tram lo speed reverse 
29-tram forward turn It 
32-pivot right 



enter (1-34) -> 
************************************************************************************* 



Closed Loop Test 

When element 3 of the main menu (menu 
1) is selected, the operator is presented 
a menu (The closed loop control menu — 
menu 6) through which a machine appendage 
can be tested for accurate positioning 
when using sensor feedback for valida- 
tion. In the tests, embedded software 
algorithms compensate for machine control 
variables such as gear backlash and 
hydraulic response times. The primary 
control algorithm is called the servo. 
In servo, a requested target value is 
pursued by activating the appropriate 
machine appendage and monitoring the out- 
put from the sensor attached to the 
appendage. As the machine appendage 
closes in on the requested target, then 
the algorithm deactivates the appendage 
control, which indicates the requested 
target was reached. 

Operation of this mode begins by 
requesting the operator to fill in the 
tables provided by items 1, 2, and 3 of 
menu 6. Then the operator goes to the 
execution mode to select a primitive to 



test. The various tables and menu items 
are described in the following sections. 

MENU 6 
***************************************** 

Closed Loop Control Menu 

1. control table 

2. simulation table 

3. hysteresis table 

4. execution mode 

5. exit 

enter (1-5) -> 
***************************************** 

Control Table 

The first table the operator must fill 
in is the control table (see menu 7). 
This table identifies each of the machine 
primitives and shows operator changeable 
parameters including a target, a re- 
quested ramp rate, and a maximum target. 
These operator changeable items are 
described in the following sections. 



13 



MENU 7 

A ************************************************************************* 

Closed Loop Control Table 



Function 
1 -conveyor 
2-conveyor swing 
3-shear 
4-stab jack 
5-gathering head 

Function 
6 -tram slow 
7-tram fast 
8-tram reverse slow 
9-tram reverse fast 

Function 

10-pivot left 

11-pivot right 

12-tram reverse left 

13-tram reverse right 

14-tram forward left 

15-tram forward right 

select an operation 

1-update 2-exit enter (1-2) -> 

************************************************************************************* 



Target(deg) 


Req ramp rate(deg/sec) 


Max target(deg) 


1.23 


4.7 


20 


2.45 


5 


95 


24.66 


3.1 


45 


6.90 


12.1 


25 


10 


1.8 


24 


Target(feet) 




Max target(feet) 


11.3 




200 


33 




150 


121 




140 


122 




140 


Target(deg) 




360 


45 




360 


22 




180 


34 




180 


50 




270 


23 




270 


12 







Target 

The target value is a position in 
degrees or feet that the operator wants 
the primitive on the machine to achieve. 
The target value is actually the scaled 
output from a sensor or collection of 
sensors associated with a particular 
primitive. Presently, only primitives 1 
through 5 use sensors to determine 
position. 

Requested Ramp Rate 

This parameter is associated only with 
the first five primitives. Its value 
is given by operator input, in degrees 
per second. The requested ramp rate is 
only used when the operator requires a 



primitive to operate at less than full 
speed, and then the speed is determined 
by the values supplied in this table 
item. The selection of using a requested 
ramp rate or full speed is provided 
through menu 10 (type of execution menu). 

Maximum Target 

The value entered into this table item, 
is used by the software to set the maxi- 
mum allowable limit for a target, as 
determined by the scaled sensor output. 
This number is the maximum output that a 
sensor can provide under normal operating 
conditions. If this number is ever 
exceeded, the computer would indicate a 
possible hardware failure in the system. 
As a closed loop test is executed, values 



14 



from menu 7 
task. 



are supplied to a software 



Closed Loop Test, Execution Mode, Algo- 
rithm Description 

The algorithms created for the execu- 
tion mode are identified in figure 6. 
The operator begins execution by select- 
ing a primitive; from then on, the pro- 
cess is automatic. There are five tasks 
that provide the closed loop algorithm. 
Each task is an Independent piece of 
software that runs concurrently with each 
of the other tasks. The purpose for each 
task is described in the following 
sections. 

Execute 

Execute is created as soon as the oper- 
ator selects a primitive function. The 
first step it performs is to collect data 
for the selected primitive from the 
appropriate data tables. Next, execute 
creates a second task called spawner. 
Then it goes into a sleep state where it 
waits for one of two possible occur- 
rences; one, the operator interrupts the 
process; or two, the computer halts the 
process when the primitive achieves a 
target within the hysteresis band. 

Spawner 

The spawner task's purpose is to create 
the entire closed loop cycle. First the 




FIGURE 6.— Closed loop test algorithm. 



analog data task, then the servo task, 
and, finally, the ramper task is created. 
Spawner provides each of the tasks with 
primitive specific initialization data. 
After these tasks are created, Spawner 
dies. 

Analog Data 

This task continuously provides primi- 
tive specific, conditioned sensor data, 
as requested. 

Servo 

The servo algorithm begins by waiting 
for a message for a target value from the 
ramper to which a particular primitive is 
supposed to achieve. As soon as a target 
value is received, the present position 
of the primitive is determined, and is 
compared to the target value. If the 
primitive position is within the hystere- 
sis boundaries of the target, then no 
action is taken. However, if the primi- 
tive position is outside the hysteresis 
boundaries of the target, then action is 
taken to move the primitive to the 
appropriate position. 

Ramper 

Ramper is a software task that outputs 
to the servo, varying numbers at a con- 
stant rate that represent target values. 
The numbers increase or decrease towards 
some final number that represents the 
final target. When the final target 
number is achieved, it is continuously 
output at a constant rate until the 
closed loop process is halted. 

Simulated Machine Operation 

Item 2 (simulation table) from the 
closed loop control menu (menu 6) pro- 
vides a simulated machine, mode of opera- 
tion, and is used only as a computer 
debugging tool, and is not used to con- 
trol the mining machine. In fact, when 
this mode is used, the computer should 
not be connected to the mining machine. 
The numbers entered into the simulation 
table are used to cause a digital- 
to-analog (D-A) converter to simulate the 



15 



output of a particular sensor attached to 
a particular moving appendage on the min- 
ing machine. The creation of this mode 
was done primarily to permit the system 
developers to test software algorithms 
without having to use a 50-st mining 
machine to debug the software. Use of 
this mode requires that the outputs of 
the appropriate channels of a D-A card be 
attached to the appropriate channels of 
the analog-to-digital (A-D) converter 
card. The table provided to the user is 
shown in menu 8. 

Descriptions of the operator changeable 
parameters for items in menu 8 follow. 

Ctrl Ramp Rate 

The numbers entered for each of the 
machine primitives are the actual rate at 
which the analog signal will change for a 
particular channel of the D-A card. 



Lag time 

The operator-entered number represents 
a machine constant for gear backlash and 
hydraulic system delays. 

Hysteresis Table (See Menu 9) 

This table (displayed when item 3 of 
menu 6 is selected) presents operator 
changeable parameters that take into 
account the inaccuracies associated with 
controlling machine appendages on the Joy 
16 CM mining machine. The parameters Ex_ 
out, Ex_in, Dep_out and Dep_in are posi- 
tions in space about a target to which 
the appendage is to move. Use of these 
parameters, in the closed loop mode of 
operation, eliminate instabilities inher- 
ent in machine control environments. A 



MENU 8 
****************************************************************************** 

Simulated Machine Operation 
Function 

1 -conveyor up 

2-conveyor down 

3 -conveyor swing up 

4-conveyor swing down 

5-shear up 

6-shear down 

7 -stab jack up 

8 -stab jack down 

9-gathering head up 
10-gathering head down 

Function 

11-tram slow 

12-tram fast 

13-tram reverse slow 

14-tram reverse fast 

15-pivot left 

16-pivot right 

17-tram reverse left 

18-tram reverse right 

19-tram forward left 

20-tram forward right 

Select an operation 

1-update 2-exit enter (1-2) -> 

************************************************************************************* 



Ctrl Ramp Rate(deg/sec) 
1.2 


Lag time(sec) 
1 


2.5 


1.5 


5.0 


1.6 


3.4 


2.1 


3.4 


0.3 


2.1 


1.5 


3.4 


0.6 


2.9 


1.2 


5.9 


0.9 


2.9 


0.8 


Ctrl Ramp Rate(f eet/sec) 
1.4 


Lag time(sec) 
3.2 


3.2 


1.9 


4.3 


1.2 


6.8 


0.7 


19.1 


0.8 


19.1 


0.5 


9.8 


2.4 


2.4 


0.6 


15.1 


0.9 


20 


2.3 



16 



more detailed description of these param- 
eters will be subsequently published.^ 

When a closed loop cycle begins, values 
are taken from this table and are used to 
determine if the primitive is within a 
target window. 

MENU 9 
***************************************** 

Hysteresis Levels Table 
(all parameters are in degrees) 
Primitive Ex_out Ex_in Dep_out Dep_in 
1-conveyor 1.6 1.3 1.45 1.2 
2-conveyor 

swing 4.5 3.9 4.5 4.6 
3-shear 2.7 0.4 2.9 0.4 
4-stab 

jack 4.0 2.3 4.0 1.6 
5-gathering 

head 2.9 2.2 2.9 2.2 

Select an operation 

1-update 2-exit enter (1-2) -> 
***************************************** 

Execution Mode 

This is a working part of menu 6. From 
here, machine cycles are executed based 
on parameters entered in the tables 
listed in the closed loop control menu. 
Entry into this mode begins as shown in 
menu 10. From this menu, there a four 
selectable types of execution. A de- 
scription for each is provided in the 
following text. 

MENU 10 
***************************************** 

Type of Execution 
1-machine data, full speed 
2-machine data, requested ramp rate 
3-simulated machine data, full speed 
4-simulated machine data, requested ramp 

rate 
5-exit this mode 

enter (1-5) -> 
***************************************** 

"For further information, contact John 
Sammarco, Pittsburgh Research Center, 
Bureau of Mines, Pittsburgh, PA. 



Machine Data-Full Speed 

This mode of operation causes a 
selected machine primitive to move from 
its present position, as determined by 
sensor input, to a particular target as 
set in the closed loop control table 
(menu 7) and as measured by sensor input. 
The machine primitive will move at the 
maximum speed possible, limited only by 
the physical characteristics of the 
machine. 

Machine Data-Requested Ramp Rate 

This mode of operation causes a 
selected machine primitive to move from 
its present position, as determined by 
sensor input, to a particular target as 
set in the closed loop control table 
(menu 7) and as measured by sensor input. 
The machine primitive will move at a 
software controlled ramp rate as deter- 
mined by the Req_Ramp_Rate as input by 
the operator. 

Simulated Machine Data-Full Speed 

This mode of operation causes a 
selected computer output port to turn on 
and stay on until the software has con- 
cluded that a target was reached as 
determined by a simulated sensor input. 
The speed of execution is a measurement 
of the maximum response that can be 
expected from this set of hardware and 
software. 

Simulated Machine Data-Requested Ramp 
Rate 

This mode of operation causes a 
selected computer output port to cycle on 
and off at a software controlled ramp 
rate, until the software has concluded 
that a target was reached, as determined 
by a simulated sensor input. This cycle 
provides a base for testing closed loop 
control software algorithms. 

After the mode of execution is 
selected, the operator selects the primi- 
tive he or she wishes to execute from 
menu 11. 



17 



MENU 11 
***************************************** 

Closed Loop Control Selector 

1 -conveyor 

2-conveyor swing 

3-shear 

4-stab jack 

5-gathering head 

6 -exit 

select a primitive to execute (1-6) -> 
***************************************** 

Browser Mode 

This mode is item 4 as selected from 
the main menu (menu 1). It gives the 
local operator a complete, instantaneous 
output from every sensor presently con- 
nected to the A-D converter card. The 
local terminal output is shown in menu 
12. 

MENU 12 
***************************************** 

Browser Mode Output 



chan 





= 


00.00 


chan 


1 


= 


00.00 


chan 


2 


= 


00.00 


chan 


3 


= 


00.00 


chan 


4 


= 


00.00 


chan 


5 


= 


00.00 


chan 


6 


= 


00.00 


chan 


7 


= 


00.00 


chan 


8 


= 


00.00 


chan 


9 


= 


00.00 


chan 


10 


= 


00.00 


chan 


11 


^ 


00.00 


chan 


12 


= 


00.00 


chan 


13 


= 


00.00 


chan 


14 


= 


00.00 


chan 


15 


= 


00.00 


chan 


16 


= 


00.00 


chan 


17 


= 


00.00 


chan 


18 


= 


00.00 


chan 


19 


= 


00.00 


chan 


20 


= 


00.00 


chan 


21 


= 


00.00 


chan 


22 


= 


00.00 


chan 


23 


= 


00.00 


chan 


24 


= 


00.00 


chan 


25 


= 


00.00 


chan 


26 


= 


00.00 


chan 


27 


= 


00.00 


chan 


28 


= 


00.00 


chan 


29 


= 


00.00 


chan 


30 


= 


00.00 


chan 


31 


= 


00.00 


***************************************** 


Scripting 


Mode 











The scripting mode is a software appli- 
cation that permits the user to chain 



together a series of machine movements 
that can be executed with a single key- 
stroke. As in all of the TAMME applica- 
tions, it is menu driven. The operator 
activates it from the main menu (menu 1) 
by selecting item 5. The first screen 
(menu 13), displays three applications, 
which are described in the following 
section. 

MENU 13 
ft**************************************** 

Scripting Mode Menu 

1-read a script 

2-write a script 

3-act out a script 

4-quit 

enter (1-4) -> 

***************************************** 

Read a Script 

This mode provides a directory of 
available scripts. Generally, the names 
of the scripts will be descriptive of the 
process to be performed. Menu 14 shows 
the contents of the setup script. Each 
element is numbered and the execution 
parameter is identified. The script, 
when executed, will begin with line num- 
ber 1 and end with the last line number 
shown. Modification of a script must be 
done using the write a script Mode. 

Write a Script Mode 

There are nine possible scripts that 
can be created. Each has a built-in 
default identifier, but these can be 
changed as required as shown in menu 15. 
Creation of a script is as simple as 
answering a series of questions at the 
prompts provided (a prompt is represented 
by ->). Menus 16 through 18 show the 
operators interactions in the process of 
making or changing a script. 



18 



MENU 14 
***************************************** 

Script Directory 



MENU 16 
***************************************** 



Script Directory 






- setup 


1 


- tramtoface 


2 


- findstart 


3 


- firstcut 


4 


- produce 


5 


- fillshuttle 


6 


- backout 


7 


- movenew 



8 - shutdown 

9 - exit 
Select a script to show (0-9) ->0 

Script no. 1 

Line # primitive 

1 control power relay 

2 pump run control 

3 control power relay 

4 tram lo speed forward 

5 left tram slow 

6 drum extension out 

7 pivot right 

8 turn off all latches 
***************************************** 

MENU 15 
***************************************** 

Script Directory 

- setup 

1 - tramtoface 

2 - findstart 

3 - firstcut 

4 - produce 

5 - fillshuttle 

6 - backout 

7 - movenew 

8 - shutdown 

9 - exit 

Select a script name to change (0-9) ->6 
Enter the new name (maximum of 8 letters) 

->backof f 
***************************************** 








- setup 






1 


- tramtoface 






2 


- findstart 






3 


- firstcut 






4 


- produce 






5 


- fillshuttle 






6 


- backout 






7 


- movenew 






8 


- shutdown 






9 


- exit 







Select a script to change 


(0-9) ->1 




Sc 


ript no. 1 




execution 


Li 


ne # primitive 


execution 


parameter 






parameter 


on 


1 


control power relay 


on 


on 


2 


pump run control 


on 


on 


3 


control power relay 


on 


12.45 


4 


tram lo speed forward 


12.45 


4.5 


5 


left tram slow 


4.5 


2.3 


6 


drum extension out 


2.3 


5.6 


7 


pivot right 


5.6 


on 


8 


turn off all latches 


on 



Script can be 20 lines long 

Enter 21 to exit 

Select a line in the script to change 

(l-21)->6 
***************************************** 

MENU 17 
***************************************** 

The script ends at the first disabled 
line. 

Enter 1 to enable this line 
Enter 2 to disable this line ->1 

Do you want a new primitive. Enter (y-n) 

->y 
***************************************** 



19 



MENU 18 



Select a primitive 



Momentary Primitives 

1-conveyor elevation up 

2-conveyor swing right 

5-conveyor reverse 

6 -shear up 

8-stab jack up 
10-gathering head up 
12-gathering head ext in 
14-drum ext in 
16-right tram slow 
18-fast tram 
19-right tram forward 
21-right tram reverse 
23-tram lo speed forward 
25-tram lo speed reverse 
27-tram forward turn right 
29-tram reverse turn right 
31-pivot left 
Latching Primitives 
33-conveyor forward 
35-control power relay 
37-turn off all latches 
select one ->22 



2-conveyor elevation down 
4-conveyor swing left 

7-shear down 

9-stab jack down 
11-gathering head down 
13-gathering head ext out 
15-drum ext out 
17-left tram slow 

20-left tram reverse 
22-left tram reverse 
24-tram high speed forward 
26-tram high speed reverse 
28-tram forward turn left 
30-tram reverse turn left 
32-pivot left 
34-pump run control 
36-cutting motor control 
38-exit 



For timed primitives enter seconds (0.01 to 99.99) 

For latching primitives enter (1) for on and (2) for off 

enter here ->1.45 



Remote User Operation 

A remote user port is provided by TAMME 
through its operating system and hardware 
(fig. 1). This is a serial port than can 
be used in a number of ways. A dumb 
terminal can be attached and operate the 
system. A personal computer (PC) can be 
attached, and then operate the system 
using terminal emulation software. A 
modem can be attached, which will allow 
any number of remote computers to gain 
access to TAMME using standard modem 
communication software. Remote operation 



has been confirmed using the following 
machines: Symbolics 3600, Corona Data 
System PC, and Intel 310. 

Since this is a multitasking, multiuser 
system, both the local user and the 
remote user can simultaneously interact 
with the Joy 16 CM. One user can be 
operating the machine, and another can be 
doing diagnostics. Or in a carefully 
orchestrated experiment, both users can 
run the machine. The range of possibili- 
ties are large but careful planning is 
crucial. 



20 



So far, the interactions through the 
remote port have been accomplished 
through menu-driven interfaces. The menu 
items are a limited set of what is avail- 
able to the local user. There is, how- 
ever, a special function now being built 

SUMMARY 



into the menu, that allows the remote 
port to communicate in a computer- 
to-coraputer fashion, rather than in a 
human-to-coraputer fashion, such as using 
menus. It employs a simple protocol. 



The first step towards making a Joy 16 
CM mining machine is now complete. The 
fundamental performance characteristics, 
under computer control, have been deter- 
mined. The next areas of activity will 
be to experiment with a variety of 
devices that will ultimately give the 
machine knowledge of its position in 
respect to the coal, the roof, and the 
general work area. Additionally, experi- 
ments will be performed in the areas of 
machine health, fault diagnosis, and 
interaction with mining machine support 
equipment. All of these experiments will 
begin as independent entities. As they 
evolve and produce practical hardware and 
software, they will be integrated within 
the TAMME system. To facilitate this 
evolution, TAMME is presently being 
enhanced by connection of a high-speed, 




multitasking, distributed, microcontrol- 
ler-based network. TAMME will act as the 
master in this network. The newly devel- 
oped application devices, hardware, and 
software will be attached to a node in 
the network, as shown in figure 7 (a node 
is one microprocessor, which has built-in 
communication and intelligent control 
algorithms). Data transferred between a 
node and TAMME will be very high level. 
This mode of operation will relieve TAMME 
of detail work and permit it to concen- 
trate on its main function being process 
orchestrator. 

The Bureau has developed a tool that 
provides access to mining machines, 
through which researchers can perform 
experiments, toward the goals of in- 
creased production and operator safety. 
Software algorithms provided by TAMME 
allow experimenters to completely define 
the control characteristics of a machine 
and then implement these characteristics 
in higher level software programs. With 
these higher level programs the TAMME 
system demonstrated control accuracy that 
is far superior to what a human operator 
can provide. Remote user operation of 
machine functions proves that other com- 
puters can be added to the system for 
additional system enhancement. 

Although TAMME was constructed to be a 
research tool, its flexible design makes 
it easily reconf igurable to a production 
tool. In fact, some of the software 
algorithms already created could be used 



for production without any changes. 



And 



BITBUS NETWORK 
FIGURE 7.-TAMME and bitbus network. 



even though the hardware was set up for a 
Joy 16 CM machine, its modular I-O con- 
figuration can be quickly adapted to most 
any machine by simply changing a plug-in 
module. 

The development and documentation of 
this system is provided in hopes of mak- 
ing it easy for others to pursue the 
goals of making coal mining more economi- 
cal and safer. 



INT.-BU.OF MINES,PGH.,PA. 28769 



U.S. GOVERNMENT PRINTING OFFICE: 1988-0-547-389 



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